Modular managed pressure drilling choke system

ABSTRACT

The modular managed pressured drilling system provides multiple skids with individual chokes and PRVs on the skids. These skids secure to one another to construct a modular MPD system that provides the proper equipment for the drilling operation. An inlet flow block and an outlet flow block are secured to each skid. The flow blocks provide multiple apertures to provide different pathways for the drilling fluid through the flow blocks. The flow blocks may direct the fluid through a first choke, a second choke, a pressure relief valve, or a bypass.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation in part of U.S. patent applicationSer. No. 15/896,042 entitled MODULAR MANAGED PRESSURE DRILLING CHOKESYSTEM filed on Feb. 13, 2018, which is a continuation in part of U.S.Patent Application Ser. No. 62/469,258 entitled MODULAR MANAGED PRESSUREDRILLING CHOKE SYSTEM filed on Mar. 9, 2017 and a continuation in partof U.S. Patent Application Ser. No. 62/458,451 entitled MODULAR MANAGEDPRESSURE DRILLING CHOKE SYSTEM filed on Feb. 13, 2017.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

REFERENCE TO A MICROFICHE APPENDIX

Not Applicable.

RESERVATION OF RIGHTS

A portion of the disclosure of this patent document contains materialwhich is subject to intellectual property rights such as but not limitedto copyright, trademark, and/or trade dress protection. The owner has noobjection to the facsimile reproduction by anyone of the patent documentor the patent disclosure as it appears in the Patent and TrademarkOffice patent files or records but otherwise reserves all rightswhatsoever.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to managed pressure drilling (MPD) andunder balanced drilling (UBD) operations. More specifically, the presentinvention is related to a modular MPD system and a method of managingpressure with a modular system that allows rig personnel to implementthe needed components for the drilling operation. The present inventionis also related to a modular MPD system that enables the user to add orremove components needed for the MPD system based upon the drillingconditions of an anticipated project or risk assessment plan and costsfor the operation.

SUMMARY OF THE INVENTION

The Modular MPD is a new modular low cost Managed Pressure Drillingmanifold that provides a single manifold that can be assembled as 1 fullMPD skid incorporating two chokes for 100% equipment redundancy duringMPD operations and a full bore bypass line for well conditions notrequiring MPD operations. The present invention provides a low cost MPDsolution to meet the needs of customers drilling unconventional wells inwhich the safety benefits of being able to apply surface back pressureare desirable but the cost associated with having a full conventionalMPD system is not economically viable.

When combined as a single, assembled MPD skid incorporating multiplechokes, including but not limited to a single choke or two or morechokes, and a full bore bypass line, a remote HMI (human machineinterface) controls the unit in conjunction with a coriolis meter skidand programmable PRV (pressure relief valve). Such a system is capableof a full range of MPD operations due to the options provided by themodular components. The manifold will be operated by rig personnel withadditional control and monitoring functionality available via the HMI.

The system provides a modular MPD manifold that can be separated intothree (3) or more individual skids. The modular MPD system enables therig personnel to separate the manifold for use as two (2) or moreindividual single set point manifolds for lower cost simple surface backpressure MPD operations either with or without the bypass and theprogrammable PRV.

Such versatility allows the manifold to meet the needs of variousprojects and budgets.

For a single set point choke system, the HMI will be provided directlyto the driller for operation. Such a system can serve as an unmannedrental.

Such a modular MPD system provides marketing value by enabling singleset point function. If the rig personnel require additional equipmentand support, the full system can be readily deployed and integrated tothe system.

Users assemble the modular MPD of the present invention from variousoptional components including a single choke, two or more chokes, a PRV,and a bypass. The user can add the additional components to the manifoldwhile a component remains attached to the flowline of the RCD. Themanifold may be assembled to increase the number of components while themanifold is connected to the flowline.

It is an object of the present invention to provide a modular MPDsystem.

It is also an object of the present invention to provide multiple skidsthat can be used independently and in coordination with each other.

It is also an object of the present invention to reduce costs of an MPDoperation.

It is also an object of the present invention to maximize efficiency ofthe drilling equipment.

It is also an object of the present invention to provide a modularsystem that enables the user to customize the configuration needed forthe drilling operation.

It is also an object of the present invention to enable rig personnel toquickly and easily add additional skids for the MPD operation if theadditional skids are needed.

It is also an object of the present invention to reduce the costs of MPDdrilling.

It is also an object of the present invention to reduce the amount ofequipment needed at a drilling site to the minimum amount required.

It is also an object of the present invention to provide a low cost MPDsolution.

It is also an object of the present invention to maintain the processpressure at or near the set point value.

In addition to the features and advantages of the present invention,further advantages thereof will be apparent from the followingdescription in conjunction with the appended drawings.

These and other objects of the invention will become more fully apparentas the description proceeds in the following specification and theattached drawings. These and other objects and advantages of the presentinvention, along with features of novelty appurtenant thereto, willappear or become apparent in the course of the following descriptivesections.

BRIEF DESCRIPTION OF THE DRAWINGS

In the following drawings, which form a part of the specification andwhich are to be construed in conjunction therewith, and in which likereference numerals have been employed throughout wherever possible toindicate like parts in the various views:

FIG. 1 is a perspective view of one embodiment of the present invention;

FIG. 2 is a front view thereof;

FIG. 3 is a front view thereof;

FIG. 4 is a rear perspective view thereof;

FIG. 5 is an environmental view thereof;

FIG. 6 is an environmental view thereof;

FIG. 7 is a perspective view of one embodiment of the present invention;

FIG. 8 is a left side view of one embodiment of the present invention;

FIG. 9 is a schematic view thereof;

FIG. 10 is a top view thereof;

FIG. 11 is a right side view thereof;

FIG. 12 is a rear view thereof;

FIG. 13 is a perspective view thereof;

FIG. 14 is an exploded view thereof;

FIG. 15 is a perspective view thereof; and

FIG. 16 is an exploded view thereof.

DETAILED DESCRIPTION

The present invention is designed to be as modular and as mobile aspossible to allow simple installation of the MPD system at the drillingrig. The MPD system provides separable skids that the user can attach ordetach to adjust the functionality of the MPD system. The user may suchselect optional components such as the additional choke(s), bypass, andPRV.

Such versatility in operation enables the user to acquire the preciseamount of equipment needed for the job. If particular equipment is notneeded, the users do not require the full configuration. The user caninstall the skids as necessary. If increased functionality is requiredat the site, the user simply adds additional components to the system.

FIG. 1 shows the modular MPD system 100. The modular MPD system 100provides a pressure relieve value 102, an intelligent relief valve inone embodiment, flow control devices, such as chokes 104, 106, and abypass 108 with valve. The intelligent PLC controlled pressure reliefvalve 102 operates within the MPD system 100.

In one embodiment, the chokes 104, 106 are adjusted by linear actuators103. The linear actuators 103 control the opening of the chokes 104,106. The actuators 103 open and close the chokes 104, 106. Such linearactuators 103 improve the performance of the chokes 104, 106. The chokesmay also be controlled by traditional methods as well.

Each of the choke 104, 106 skids and the optional pressure relieve valve102 (PRV) skid may be configured as a single skid. In anotherembodiment, the chokes 104, 106 and the PRV 102 are provided asindividual skids 110, 112, 114. The individual skids 110, 112, 114 maybe secured together. The skids 110, 112, 114 attach in differentconfigurations to allow for different operating configurations as willbe discussed below. The system also enables attachment of bypass 108 tothe modular MPD system 100.

The MPD system can utilize various diameter electric linear actuatordrilling chokes. The choke of one embodiment operates via a linearactuator to provide additional control, quicker response, and morereliable operation.

The MPD system 100 provides a full bore bypass for increasedfunctionality. The system 100 can be configured for set point controlfor use by rig personnel. The system 100 may also be integrated as afully automated MPD system. The modular components, such as the PRV 102,chokes 104, 106, and bypass 108 on individual skids 110, 112, 114 allowthe system 100 to be configured for the drilling operation and to reducethe costs associated with drilling.

FIGS. 2 and 3 show a choke 106 on skid 114. FIG. 2 shows the choke 106assembled with the bypass 108. The choke 106 provides an inlet 116 andoutlet 117. Valves 118, 122, 120 control the flow through the choke 106and bypass 108. The valves of the chokes and bypass may be manuallyadjusted or automatically actuated.

FIG. 4 shows a view of the PRV 102 on individual skid 110.

FIGS. 5 and 6 show the skids 110, 112, 114 secured to each other at thebase. Support arms 124, 124 a, 124 b stabilize the top of the skids. Theuser then attaches the cables, chains, ropes, links, or harness to theskids to lift and move the skids 110, 112, 114 as a system 100.

To lift multiple skids, such as skids 110, 112, a lifting body 136secures additional cables, etc. to the skids 110, 112, 114 for liftingthe system 100.

FIG. 7 shows a view of the choke 106 and valves 118, 122 with inlet 116and outlet 117. The valves may open or close depending upon use of thechoke 106. In one embodiment, a blank flange seals the inlets andoutlets of the components that are not used.

FIG. 8 shows another view of the MPD system 100 with the chokes 104,106, PRV 102, and inlet 116 and openings 119, 119 a of flow blocks thataccept fluids into the respective components. The chokes 104, 106 areutilized by valves 118, 118 a. The chokes 104, 106 attach to each othervia conduits 170, 172 to allow the fluids to flow through the differentchokes 104, 106, and PRV 102 via conduits 170, 172.

Conduits connect the PRV 102, chokes 104, 106, and bypass 108 to eachother. Conduits 170, 172 connect the components for operation. Theconduits secure at openings within the flange of the components, such asPRV 102 and chokes 104, 106. If no component is attached at the openingof a component placed into operation at the drilling site, the openingis closed with a blank flange.

If a component attaches to another component, two conduits attach theopenings of the two components. Two conduits attach each component toeach other to allow fluids to flow to the next component and return tothe previous component. A sample of the two conduits connecting twocomponents can be seen at conduits 107, 109 of FIG. 1 connecting thechoke 106 with bypass 108.

FIG. 9 shows the multiple configurations of the modular MPD system. Asdiscussed above, the modular MPD system enables the user to configurethe MPD system for the specific drilling operation. The end user canthen select only the necessary equipment for the drilling operation. Theuser can minimize the usage of equipment to reduce operating costs.

Configurations 152, 154, 156, 158, 162 show the different configurationsof the modular MPD system with optional PRV. Configuration 152 isconstructed from two chokes, a bypass, and a PRV. Configuration 154 isconstructed from a single choke and a bypass. Configuration 156 isconstructed from two chokes and a bypass. Configuration 158 isconstructed from a bypass, a choke, and a PRV. Configuration 162 isconstructed from a single choke.

Many different configurations are possible involving additional chokes.Installing the components, such as the chokes and optional PRV, onindividual skids enables multiple configurations. The user can thenconfigure the appropriate setup for the drilling conditions. If thedrilling conditions require more components, the user can easily add theadditional components to meet the needs required by the drillingconditions. The additional components of one embodiment can be addedwithout requiring disconnection of the MPD manifold from the flowlinefrom the RCD.

Other configurations not shown in FIG. 9 include, but are not limitedto:

single choke and PRV;

dual chokes; and

dual chokes and PRV.

FIG. 10 shows a top view of one embodiment of the present invention inwhich PRV 102, chokes 104, 106, and bypass 108 construct the system.Conduits 107, 109 connect the choke 106 with bypass 108. Conduits 170,176 connect chokes 104, 106. Conduits 172, 174 connect choke 104 withPRV 102.

The fluid flows through conduits 107, 109, 170, 172, 174, 176 to thedifferent components of the system. The fluid enters the system at aninlet of the system. The fluid then travels to the other components atthe inlet for each component. In one embodiment, each component providesan inlet and an outlet for fluid to enter and exit the component. In oneembodiment, each component provides a first API flow block that servesas an inlet and a second API flow block that serves as an outlet.

Each API flow block provides multiple openings to allow fluid to flowthrough the flow block in different configurations. These openings mayserve as an inlet or an outlet depending on the flow of the fluidthrough the flow block.

FIG. 11 shows the outlet 117 of bypass 108. The fluid flows out fromoutlet 117 away from the system 100. The fluid passing through thecomplete system 100 may flow through bypass 108 to chokes 106, choke104, PRV 102 and return to choke 104, choke 106, and bypass 108. Thefluid can flow from PRV 102 to choke 104 through conduit 174. The fluidcan flow from choke 104 to choke 106 through conduit 176. The fluid canalso flow from choke 106 to bypass 108 through conduit 109 and outoutlet 117.

FIG. 11 also shows the components on each individual skid 110, 112, 114.PRV 102 installs onto skid 110. Choke 104 installs onto skid 112. Choke106 installs onto skid 114.

FIG. 12 shows the openings 119, 119 a of the flow blocks of a choke. Theopenings 119, 119 a are open to allow fluid to flow through the openings119, 119 a of the choke. Conduits attach to the flow blocks at openings119, 119 a for fluid to flow through the openings 119, 119 a and theconduits. If another component does not attach to the choke shown inFIG. 12, the user installs a blank flange across openings 119, 119 a.

FIGS. 13 and 14 show perspective views of the system. FIG. 13 shows thecomponents connected while FIG. 14 shows an exploded view. Conduits 107,109, 170, 172 connect the components to one another. Conduits 107, 109connect bypass 108 to choke 106. Conduit 170 connects chokes 104, 106.Conduit 172 connects choke 104 to PRV 102.

FIG. 13 shows inlet 116 of bypass 108 to which the flowline from the RCDattaches. Openings 119 b, 119 c in the flow blocks allow attachment ofconduits for the flow of fluids into the components. However, suchopenings 119 b, 119 c are closed as shown in FIG. 14 with blank flanges178, 178 a.

FIG. 14 shows the exploded view of the connections of the conduits 107,109, 170, 172 at the openings of the flow blocks 180. The conduitsattach at the openings of the flow blocks to control the flow of thefluid through the components.

FIGS. 15 and 16 show more perspective views of the system. FIG. 15 showsthe components connected while FIG. 16 shows an exploded view. Conduits109, 174, 176 connect the components to one another. Conduit 109connects bypass 108 to choke 106. Conduit 176 connects chokes 104, 106.Conduit 174 connects choke 104 to PRV 102.

FIG. 15 shows outlet 117 of bypass 108 directing the fluid to themetering manifold. Openings in the flow blocks allow attachment ofconduits for the flow of fluids into the components.

FIG. 16 shows the exploded view of the connections of the conduits 109,174, 176 at the openings of the flow blocks. The conduits attach at theopenings of the flow blocks to control the flow of the fluid through thecomponents.

Continuing to refer to FIG. 16, the openings of the flow blocks of PRV102 may be closed if no additional components are added onto the side ofPRV 102. Otherwise, conduits may attach at the opening of PRV 102 to addadditional components to the system at PRV 102.

FIGS. 14 and 16 show the modular components. The individual skids 110,112, 114 enable different configurations of the components of thesystem. The user can configure the components needed for the drillingoperation. Such modular capability and configurability of the MPD systemdecreases costs of the operation by allowing the user to install onlythe required components. If additional components are needed in thefuture, the user can quickly add the additional components via conduitsand the openings of the flow blocks.

From the foregoing, it will be seen that the present invention is onewell adapted to obtain all the ends and objects herein set forth,together with other advantages which are inherent to the structure.

It will be understood that certain features and subcombinations are ofutility and may be employed without reference to other features andsubcombinations. This is contemplated by and is within the scope of theclaims.

As many possible embodiments may be made of the invention withoutdeparting from the scope thereof, it is to be understood that all matterherein set forth or shown in the accompanying drawings is to beinterpreted as illustrative and not in a limiting sense.

What is claimed is:
 1. A modular managed pressure drilling system for awell, the system comprising: a first skid; a first choke secured to thefirst skid; a first inlet flow block connected to the first chokewherein the first inlet flow block directs fluid into the first chokefrom the well, wherein the first inlet flow block provides at least twoopenings from which the fluid flows through the first inlet flow,wherein one of the openings directs the fluid into the first choke; afirst outlet flow block connected to an outlet of the first chokewherein the fluid exits the first choke through the first outlet flowblock, wherein the first outlet flow block provides at least twoopenings from which the fluid may flow through the first outlet flowblock; a second skid; a first component secured to the second skidwherein the fluid flows from the first choke to the first component. 2.The system of claim 1, wherein the first outlet flow block connects tothe outlet of the first choke wherein the first outlet flow blockdirects the fluid from the first choke to the first component; a flangeof the first outlet flow block wherein the flange accepts a blank flangeto close at least one of the openings of the first outlet flow block. 3.The system of claim 1 further comprising: a bypass allowing the fluid tobypass the first choke and the first component.
 4. The system of claim 3wherein the bypass is a 4 1/16 inch full bore bypass.
 5. The system ofclaim 1 wherein the first component is a second choke.
 6. The system ofclaim 5 wherein the first choke and the second choke are three inchelectrically actuated linear drilling chokes.
 7. The system of claim 1wherein the first component is a pressure relief valve.
 8. The system ofclaim 7 further comprising: a human machine interface/programmable logiccontroller (HMI/PLC) connected to the managed pressure drilling system.9. The system of claim 8 wherein the HMI/PLC controls the pressurerelief valve.
 10. The system of claim 1 wherein the first skid attachesto the second skid at a base of each skid.
 11. The system of claim 1wherein the first choke is an electrically actuated linear drillingchoke.
 12. A modular managed pressure drilling system for a well, thesystem comprising: a first skid; a first choke secured to the firstskid; a first inlet flow block connected to an inlet of the first chokewherein the first inlet flow block directs fluid into the first chokefrom the well; a first outlet flow block connected to an outlet of thefirst choke wherein the fluid exits the first choke through the firstoutlet flow block; a second skid attachable to the first skid; a firstcomponent secured to the second skid wherein the fluid flows from thefirst choke through the first outlet flow block to the first component;a bypass connected to the first inlet flow block, the bypass directingthe fluid to bypass the first choke and the first component to limit thefluid flowing through the first choke and the first component; the firstinlet flow block directing the fluid to flow in two separate directions,a first direction that directs the fluid through the bypass to bypassthe first choke and the second direction that directs the fluid throughthe first choke.
 13. The system of claim 12, wherein the first outletflow block connects to the outlet of the first choke wherein the firstoutlet flow block directs the fluid from the first choke to the firstcomponent; a flange of the first outlet flow block wherein the flangeaccepts a blank flange to close an opening of the first outlet flowblock.
 14. The system of claim 12 wherein the first component is asecond choke.
 15. The system of claim 14 wherein the first choke and thesecond choke are three inch electrically actuated linear drillingchokes.
 16. The system of claim 12 further comprising: a third skidattachable to the first and second skid; a pressure relief valveattached to the third skid.
 17. The system of claim 12 wherein the firstskid attaches to the second skid at a base of each skid.
 18. A modularmanaged pressure drilling system for a well, the system comprising: afirst skid; a first choke secured to the first skid; a first inlet flowblock connected to an inlet of the first choke wherein the first inletflow block directs fluid into the inlet of the first choke from thewell, wherein the first inlet flow block provides a first opening and asecond opening from which the fluid flows through the first inlet flow,wherein the first opening directs the fluid into the first choke,wherein the second opening of the first inlet flow block directs thefluid to bypass the first choke; a first outlet flow block connected toan outlet of the first choke wherein the fluid exits the first chokethrough the first outlet flow block, wherein the first outlet flow blockprovides at least two openings from which the fluid may flow from thefirst outlet flow block; a second skid attachable to the first skid; afirst component secured to the second skid wherein the fluid flows fromthe first choke to the first component; the first outlet flow blockconnected to the outlet of the first choke wherein the outlet flow blockdirects the fluid from the first choke through the first outlet flowblock to the first component; a bypass connected to the first inlet flowblock directing the fluid to bypass the first choke and the firstcomponent; wherein the first inlet flow block directs the fluid in twoseparate directions, a first direction that flows through the bypass tobypass the first choke and a second direction through the first choke.19. The system of claim 18 further comprising: a third skid attachableto the first and second skid; a second component attached to the thirdskid; and the bypass directing the fluid to bypass the first choke, thefirst component, and the second component.
 20. The system of claim 19wherein first component is a second choke and the second component is apressure relief valve.